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Feeding Systems: Feedlot Design and Construction
Feeding Systems: Feedlot Design and Construction
Introduction
The feeding system must be well designed to achieve good cattle
performance, efficient feedlot operation and for maintaining high
environmental standards.
Design objectives
Feeding systems should
• provide livestock with free and continual access to feed
• maintain fresh and palatable feed
• minimise waste, spilled feed and spoilage
• prevent all classes of cattle from fouling the feed and escaping
from the pens
• allow easy delivery of feed
• allow for easy cleaning and removal of spoiled feed after rainfall
• not inhibit pen cleaning
• minimise environmental impacts (odour, flies, dust)
• minimise ongoing maintenance costs
• provide a safe working environment for pen riders and other
feedlot personnel.
Mandatory requirements
Compliance with
• Australian Animal Standards and Guidelines for Cattle
(DAFF, 2013).
• National Guidelines for Beef Cattle Feedlots in Australia
(MLA, 2012a).
• National Beef Cattle Feedlot Environmental Code of Practice
(MLA, 2012b).
• NFAS standards (AUS-MEAT, 2011).
Design choices
The feeding system can use either self-feeder bins or open feed bunks.
Self-feeders
Self-feeders are best suited to small and/or opportunity feedlots
which do not prepare their own rations or where rations are milled
and mixed off site.
Self-feeder in a feedlot. The open area under Advantages of self-feeders include that they
the self feeder allows buildup of manure,
odour and flies, and in wet weather it can • have their own storage bins and so need filling only once or
become boggy. The feed truck has to enter twice a week
the pen to deliver feed.
• are readily transportable, can be installed quickly, can be used
as a temporary feed-out system
• can be used elsewhere on the farm or in a small paddock or
yard to form a temporary feedlot for drought feeding
• can be moved around within pens.
SCU/pen
100 150 200
Self feeder capacity (kg) No. of self feeders
3500 3 5 6
5500 2 3 4
7500 2 2 3 A two-sided self-feeder placed on a concrete
apron and close to the fence line so that it
can be filled from outside the pen.
Feed bunks and aprons
Most commercial feedlots use open feed bunks (troughs). They
generally process their own feed and can feed-out more than once a
day. All types of rations, including those moist or containing large
amounts of coarsely chopped fibre, can be fed in troughs.
Location
Feed bunks should always be located along the fence line, never
within the pen, so that they can be filled during all weather
conditions. They should be located along the higher end of the pen
with drainage away from the bunk on both the feed road and pen
sides. This minimises boggy conditions on the pen side of the bunk
and keeps the feed road firm and accessible.
Bunk length
The length of a bunk depends on the number of cattle in the pen
and the dimensions of the pen. Bunks usually run the entire length
of the pen although some feedlots provide access gates in the top
end of their pens. The type of feed ration (bulkiness), size of the
cattle and desired feeding frequency must also be considered.
Bunk length per head
Most lot feeders would require 250 mm to 300 mm per head of
bunk space.
The temptation to design for 200 mm of bunk space per head in
Access gate at the top end of the pens order to minimise building costs may be false economy if 50 or 100
mm extra space would enhance cattle performance.
A shorter bunk space may restrict the opportunity of shy feeders to
feed, particularly during the introductory phase. In these cases, some
cattle will take longer to adapt to the high energy ration, there may
be more cases of acidosis, less uniform finishing of cattle within
pens and lower average daily weight gain of cattle within the pen.
Fence posts
Fence posts along the feed bunk may be cast into the bunk itself (for
bunks that are cast on site), located against the vertical wall of the
bunk on the pen side or on the inside of the feed bunk (for either pre-
cast or cast on site). The posts can be built into a feed bunk wall of
uniform thickness or with a locally thickened wall around the post.
A feed bunk wall of uniform thickness will make it easier to remove
accumulated waste but the wall must be thicker to prevent it
Posts cast into the concrete wall need to be from cracking or from damage during pen cleaning; this will add
treated with epoxy to prevent corrosion at
the concrete joint. substantially to the capital cost.
Local thickening of concrete around the posts, or having the posts
on the outside of the feed bunk, will make it difficult to clean
around them to remove manure that has built up against the bunk
wall and to clean along the feed trough apron. Posts that are cast
into the concrete wall need to be treated with epoxy or equivalent to
prevent corrosion at the steel/concrete joint and subsequent failure.
All steel posts need to be capped top and bottom to prevent water
entry and subsequent rusting. Top rails are highly recommended
along feed trough posts as these help to strengthen the whole feed-
bunk fence system which is continually being pushed by feeding
cattle. An expansion joint every 25 m in long cattle rails will
prevent buckling.
Restraint devices
Cattle must be prevented from entering the feed bunk and possibly
escaping. This has been achieved using a system of cables strung out
over the feed bunk, but this can make it difficult to maintain and
A rusted or broken post has been replaced clean the trough. In most modern feedlots, cattle are constrained by
with a new post bolted to the back of the design of the feed bunk back wall and a single cattle rail.
the wall.
An adjustable height cable below the cattle rail or an adjustable rail
will restrain a range of cattle sizes in a pen.
The judicious use of an electric wire adjacent the cattle rail or top
cable can help teach cattle not to press against the restraint system.
Cross-sectional dimensions
The cross-sectional area of the trough determines the amount of feed
that can fit into the trough per unit length. If the cross-sectional
area is too small frequent filling will be necessary, particularly if
silage or other bulky ingredients are fed. If the feed bunk is too
wide, feed pushed to the back of the bunk is less accessible and
cattle are tempted to step into the trough to try to reach it.
Feed bunks should have vertical external faces on either side for
ease of removing built-up manure and spilt grain. Outwardly sloping
sides make wastes trapped around them difficult to remove, but may
reduce damage by the feed truck.
The inside of the feed bunks should be smooth with rounded Expansion joints prevent buckling of steel
corners. Square inner corners will trap inaccessible feed allowing it cattle restraint in hot weather.
to become mouldy or stale, and are also difficult to clean.
Feed bunks should allow rainwater to drain, preferably by having
drain holes or slots at intervals along the length of the trough.
These drainage points need to be large enough that they do not get
blocked. Water can also drain if a shorter feed bunk is left open at
the end. Adequate slope (>1%) longitudinally along the feed road
and bunk enhances drainage after storms.
Feed bunks must be designed for easy filling. They should be readily
fillable from the feed road side without opening and closing gates.
Feed alleys should be straight and not curved to minimise spillages
and damage by the feed truck; the approach should have a straight
section so the truck is moving parallel to the trough when unloading.
Over the years, a wide range of different feed bunk dimensions have
been used.
Table 2 gives the dimensions of several different types. Important
dimensions are
H1 – the height of the back wall above the feed apron. This should
be 500 mm high to prevent cattle stepping into the feed bunk.
H2 – the height of the front wall above the feed road. This needs to be
higher than the back wall but not so high that it interferes with feed
delivery. Experience indicates that this should be 700-750 mm high.
Drainage points along the feed bunk
H3 – the height of the cattle restraint rail above the apron. In must be large enough so they do not
become blocked.
conjunction with H1, these dimensions allow cattle free access to feed
without rubbing or awkward bending but prevent cattle from stepping
out of the pen into the trough. H3 should be lower for smaller cattle
and therefore a restraint system where H3 can be varied is desirable.
Typically, H3 should be about 1000–1150 mm above the feed apron.
W1 – the width of the feed storage area of the bunk. In conjunction
with other dimensions, it determines the volume of feed that can be
held. If W1 is too large, cattle cannot reach feed without straining.
W2 and W3 – the thicknesses of the front and back walls. Greater
thickness provides more bunk strength but adds to the volume and
cost of concrete required.
A1 – the cross-sectional area of feed per metre length of bunk. The
Type D bunk is an old design that provided only 0.15 m2 of feed,
and has been found to be inadequate. Newer bunks provide over 0.2
m2 of feed per unit length, which is 30% more than Type D.
Bunk problems
Bends in the road and the feed bunk require extra skill from the truck Without suitable anchoring, pre-cast bunk sections can be moved
driver to avoid feed spillage. out of alignment.
Bunk aprons
Concrete apron on the pen side of the bunk provides a stable base A concrete apron extending onto the feed road will reduce any impact
against mud holes, and allows easy cleaning. on the feed truck load cells and give more control on feed delivery. The
apron should slope gently away from the bunk, but still allow the truck
driver to see into the bunk.
Posts in back wall
Local thickening of the feed bunk wall is strong but may make Posts cast into the bunk back wall of the feed bunk can rust at the
cleaning difficult. joint between the post and the back wall. Replacement posts bolted
inside of the bunk could inhibit bunk cleaning.
Cable systems above feed bunks can inhibit bunk cleaning. Posts bolted behind the back wall are more readily replaced but can
hinder cleaning along the feed apron.
External posts of old cheap railway line will inhibit cleaning along Intruding posts will make apron cleaning difficult.
the feed apron and lead to damaged posts and bunks.
Damage to the ends of feed bunks by feed trucks will be minimised Posts cast into the back wall can corrode and be damaged.
with a straight feed road and placing a steel bollard.
Cattle restraint
A fixed, two-bar cattle restraint Single steel bar cattle restraint with posts cast into the back wall of
the feed bunk
Cattle restraint using only cables. The lower cable can be adjusted to The lower cable indicates that the back of the feed bunk is too low
suit different sizes of cattle while the top cable is redundant
Trough cleaning
Feed Bunk type F with steel posts bolted to the top and rear of the
back wall, with a single-bar cattle restraint. A steel bollard prevents
damage to the end of the feed bunk.
Subgrade preparation
Before placing the slip form, the foundation material needs to be shaped
and compacted to form a firm base, or a concrete base can be used. An
uneven surface uses more concrete and leads to uneven feed bunks. The
feed apron and base can be cast in preparation for slip-form construction.
Consistency and additives
A balance between quick-setting capacity and workability is
required. Concrete needs to be workable enough to be placed into
the form and compacted, yet quick-setting enough to emerge
from the form with strength. Just enough water needs to be added
to chemically complete the hydration process with virtually no
Sealing the inside of the feed bunk with
slumping. At all times between mixing and discharge the slump epoxy resin will protect the surface from
should be within the range specified for the nominated mix. chemical attack and abrasion.
Constituent kg/m3
Aggregate 970–1100
Sand 820–970 Good concrete mix with consistent moisture
content is essential throughout the whole
Cement 330–350 slip-form process—or problems will occur.
Water 80-95
Additives – synthetic/steel fibres 0.1% by volume approx. 0.9kg/m3
Construction tolerances
The finished surface of the feed bunk should be uniform in
appearance and comply with the practical design tolerances and
client expectations.
Jointing
Contraction joints should be formed at 6 m centres.
Trial section
The construction of a trial section of bunk is highly recommended.
This will ensure that equipment, concrete mix, contractors and
techniques are able to demonstrate to the client the quality, finish
and tolerance of the finished feed bunk, and gain approval from
the client of a standard of workmanship that will be acceptable Feed Bunk G. The slip-form machine
runs on prefixed rails, then the surface is
for ongoing feed bunk work. This section should then be used as a steel trowelled.
‘standard’ for any future works to be compared against.
The trial section should be constructed using the same materials,
concrete mix, equipment and methods the contractor intends to use
Quick tips
• Self-feeders are suited best to small and/or opportunity feedlots.
• Self-feeders have their own storage bins and need filling only once or twice a week.
• Moist rations tend to ‘go off’ or spoil when stored in self-feeders for several days.
• Feed bunks should always be located along the high end of the pen along the fence line.
• Bunk space should be 250–300 mm per head in the pen.
• A bunk with a small cross-sectional area will require frequent filling, particularly with silage or
other bulky ration ingredients.
• If feed bunks are too wide, feed can be pushed to the back of the bunk and cattle are tempted to
step into the trough to try to reach it.
• Feed bunks should have enclosed vertical faces on either side for ease of removing built-up
manure and spilt grain.
• The inside of the feed bunks should be smooth with rounded corners; square corners trap feed
and are difficult to clean.
• Fence posts on the outside of the feed bunk make it difficult to remove manure build up along
the bunk wall or to clean along the feed trough apron.
• Thicker front and back walls give a feed bunk greater strength and volume, but cost more.
• Feed bunks should have drain holes or slots at intervals along the length of the trough to drain
rain water.
• Expansion joints in long cattle rails to prevent buckling.
• When the feed bunk is new, seal the inside with two-component epoxy resin to protect the
surface from chemical attack and abrasion.
Further reading
AUS-MEAT, 2011, NFAS Rules & Standards (April 2011), AUS-MEAT Limited, Brisbane, Qld.
DAFF, 2013, Australian Animal Standards and Guidelines for Cattle, Department of Agriculture, Forestry
and Fisheries, Australian Government, Canberra, ACT.
MLA, 2012a, National Guidelines for Beef Cattle Feedlots in Australia. Meat & Livestock Australia,
Sydney, NSW.
MLA, 2012b National Beef Cattle Feedlot Environmental Code of Practice. Meat & Livestock Australia,
Sydney, NSW.
Guidelines for the establishment and operation of cattle feedlots in South Australia, Department of Primary
Industries and Resources (SA) and Environment Protection Authority, 2006, Adelaide.
Victorian code for cattle feedlots, August 1995, Victorian Feedlot Commitee, Department of Agriculture,
Energy & Minerals, Melbourne.
Skerman, A 2000, Reference manual for the establishment and operation of beef cattle feedlots in Queensland,
Information Series QI99070, Queensland Cattle Feedlot Advisory Committee (FLAC), Department of Primary
Industries, Toowoomba, QLD.
Guidelines for the Environmental Management of Beef Cattle Feedlots in Western Australia, Bulletin 4550,
2002, WADo Agriculture (ed.), Western Australia Department of Agriculture, Perth, WA.
The New South Wales Feedlot Manual, 1997, NSW Agriculture, NSW Agriculture, Department of Land and
Water Conservation, Department of Urban Affairs and Planning & Environment Protection Authority, Orange.